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Kawasaki Wheel Loader 85Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual – PDF DOWNLOAD
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Kawasaki Wheel Loader 85Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
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Description
Kawasaki Wheel Loader 85Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
File Details:
Kawasaki Wheel Loader 85Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
Language : English
Pages : 500+
Size : 61.1 MB
Downloadable : Yes
Format : PDF
KAWASAKI WHEEL LOADER 85Z7 SERVICE MANUAL + PARTS MANUAL + WIRING DIAGRAMS + TROUBLESHOOTING MANUAL – PDF DOWNLOAD:
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Table of Contents:
Kawasaki Wheel Loader 85Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
FOREWORD.............................................................................. 2 CONTENTS.............................................................................. 5 MACHINE NUMBERS....................................................................... 9 SAFETY................................................................................ 11 Recognize Safety Information...................................................... 11 Understand Signal Words........................................................... 11 Follow Safety Instructions........................................................ 12 Prepare for Emergencies........................................................... 13 Wear Protective Clothing.......................................................... 13 Protect Against Noise............................................................. 14 Inspect Machine................................................................... 14 General Precautions for Cab....................................................... 15 Use Handrails and Steps........................................................... 16 Never Ride Attachment............................................................. 16 Adjust Operator’s Seat............................................................ 16 Ensure Safety Before Rising from or Leaving Operator’s Seat....................... 17 Fasten Your Seat Belt............................................................. 17 Move and Operate Machine Safely................................................... 18 Handle Starting Aids Safely....................................................... 18 Operate Only from Operator’s Seat................................................. 19 Jump Starting..................................................................... 19 Investigate Job Site Beforehand................................................... 20 Equipment of Head Guard, ROPS, FOPS............................................... 21 Provide Signals for Jobs Involving Multiple Machines.............................. 21 Keep Riders Off Machine........................................................... 22 Drive Safely...................................................................... 22 Drive Machine Safely (Work Site).................................................. 23 Drive Safely with Bucket Loaded................................................... 24 Drive on Snow Safely.............................................................. 24 Travel on Public Roads Safely..................................................... 25 Avoid Injury from Rollaway Accidents.............................................. 25 Avoid Accidents from Backing Up and Turning....................................... 26 Avoid Positioning Bucket or Attachment Over Anyone................................ 27 Avoid Tipping..................................................................... 27 Never Undercut a High Bank........................................................ 28 Dig with Caution.................................................................. 28 Perform Truck Loading Safely...................................................... 28 Avoid Power Lines................................................................. 29 Precautions for Operation......................................................... 29 Precautions for Lightning......................................................... 29 Object Handling................................................................... 30 Protect Against Flying Debris..................................................... 30 Park Machine Safely............................................................... 31 Store Attachments Safely.......................................................... 31 Transport Safely.................................................................. 32 Handle Fluids Safely−Avoid Fires.................................................. 33 Practice Safe Maintenance......................................................... 34 Warn Others of Service Work....................................................... 35 Support Machine Properly.......................................................... 35 Stay Clear of Moving Parts........................................................ 36 Support Maintenance Properly...................................................... 36 Prevent Parts from Flying......................................................... 37 Prevent Burns..................................................................... 37 Replace Rubber Hoses Periodically................................................. 38 Avoid High-Pressure Fluids........................................................ 38 Prevent Fires..................................................................... 39 Evacuating in Case of Fire........................................................ 41 Beware of Exhaust Fumes........................................................... 41 Precautions for Welding and Grinding.............................................. 41 Avoid Heating Near Pressurized Fluid Lines........................................ 42 Avoid Applying Heat to Lines Containing Flammable Fluids.......................... 42 Precautions for Handling Accumulator and Gas Damper............................... 42 Remove Paint Before Welding or Heating............................................ 43 Beware of Asbestos and Silicon Dust and Other Contamination....................... 43 Prevent Battery Explosions........................................................ 44 Service Air Conditioning System Safely............................................ 44 Handle Chemical Products Safely................................................... 45 Dispose of Waste Properly......................................................... 45 Notes for Exhaust Filter.......................................................... 46 Precautions for Communication Terminal............................................ 46 Precaution for Communication Terminal Equipment................................... 47 Articulation Stopper.................................................................. 48 SAFETY LABELS......................................................................... 49 1 COMPONENTS NAME..................................................................... 61 1 OPERATOR'S STATION.................................................................. 63 Exhaust Filter.................................................................... 63 Diesel Particulate Filter (DPF, Exhaust Filter)............................... 64 Description of DPF functions.................................................. 64 Automatic regeneration........................................................ 65 Repeated inhibiting of exhaust filter cleaning................................ 66 Cab Features...................................................................... 67 Front Console..................................................................... 68 Right Console..................................................................... 69 Fingertip Control Type........................................................ 69 Multi-Function Joystick Type.................................................. 70 Monitor Panel..................................................................... 71 Parking Brake Indicator (Red)................................................. 72 Brake Oil Low Pressure Indicator (Red)........................................ 72 Hydraulic Oil Level Indicator (Red)........................................... 72 Low Steering Oil Pressure Indicator (Optional) (Red).......................... 73 Transmission Warning Indicator (Red).......................................... 73 Communication Error Indicator (Yellow)........................................ 73 Discharge Warning Indicator (Red)............................................. 73 Engine Trouble Indicator (Red)................................................ 74 Overheat Indicator (Red)...................................................... 74 Engine Oil Low Pressure Indicator (Red)....................................... 74 Air Filter Restriction Indicator (Red)........................................ 75 Preheat Indicator (Yellow).................................................... 75 Coolant Temperature Gauge..................................................... 76 Fuel Gauge.................................................................... 76 Turn Signal Indicator (Green)................................................. 77 High Beam Indicator (Blue).................................................... 77 Work Light Indicator (Yellow)................................................. 77 Clearance Light Indicator (Green)............................................. 78 Control lever lock indicator (Red)............................................ 78 Multi Function Monitor............................................................ 79 Screen Configuration.......................................................... 79 Default Setting............................................................... 80 Basic Screen...................................................................... 81 How to Use Screens................................................................ 82 Monitor Operation............................................................. 86 Alarm Occurrence Screen........................................................... 87 Remedy........................................................................ 89 Exhaust Filter Regeneration....................................................... 92 Automatic regeneration (Auto-regeneration).................................... 92 Manual Regeneration........................................................... 94 Service Regeneration.......................................................... 94 Main Menu......................................................................... 95 Ride Control Drive Speed Setting (Optional)....................................... 96 Dual Lift Arm Auto-Leveler........................................................ 97 Height Kickout ON/OFF, Stop Height Setting.................................... 98 Lower Kickout ON/OFF, Stop Height Setting..................................... 99 Brightness Adjustment.............................................................100 Setting Menu......................................................................102 Date and Time.................................................................103 Auto Idling Stop..............................................................109 Rear View Camera Monitor......................................................111 Exhaust Filter Regeneration Inhibited.........................................113 Transmission Setting..........................................................115 Shift Change Delay Mode Setting...........................................115 Parallel/Tandem Switching Height Setting......................................117 Warm Up Operation.............................................................119 Display Item Selection........................................................121 Main Menu Display Order Change................................................123 Information Menu..................................................................125 Operation Condition...........................................................126 Maintenance...................................................................128 Troubleshooting...............................................................132 Monitoring....................................................................134 Switches, Steering Wheel and Pedals...............................................136 Hazard Switch.................................................................137 Work Light Switch.............................................................138 Parking Brake Switch..........................................................139 Neutral Lever Lock (for the Forward/Reverse Lever)............................140 Steering Wheel................................................................140 Horn Switch...................................................................140 Key Switch....................................................................141 Turn Signal Lever.............................................................142 Light Switch..................................................................143 High-Low Beam Switch..........................................................144 Accelerator Pedal.............................................................145 Brake Pedal...................................................................145 Forward/Reverse Lever/ Shift Switch...........................................146 Wiper Switch..................................................................147 Tilt, Telescopic Lever/Steering Column Tilt Pedal.............................149 Right Console / Switches..........................................................150 Right Console / Switches (Fingertip Control Type).............................150 Loading Control Levers....................................................151 Right Console / Switches (Multi-Function Joystick Type).......................153 Loading Multi-Function Joystick Lever (Optional)..........................154 Auxiliary Control Lever (Option)..............................................155 Forward/Reverse Selector Switch...............................................156 Loading Control Lever Lock Switch.............................................157 Declutch Position Switch......................................................157 Travel Mode Selector..........................................................158 Power Mode Selector...........................................................159 Fan Reverse Rotation Switch...................................................160 Secondary Steering Operation Check Switch (Optional)..........................162 Exhaust Filter Switch.........................................................162 Ride Control Switch (Optional)................................................163 Hold Switch...................................................................165 Right Console Slide Lever.....................................................165 Quick Power Switch............................................................166 DSS (Down Shift Switch).......................................................167 Horn Switch...................................................................167 Cigar Lighter (24 V DC Electrical Outlet).........................................168 Ash Tray..........................................................................168 Auto Air Conditioner..............................................................169 Mode/Temperature Control Switch...............................................171 Fan/AUTO Switch...............................................................172 Air Conditioner ON/OFF Switch.................................................172 Circulation/Fresh Air Switch..................................................172 Defroster Switch..............................................................172 Cab Heater Operation..........................................................173 Cooling Operation.............................................................174 Defroster Operation...........................................................175 Cool Head/Warm Feet Operation.................................................175 Tips for Optimal Air Conditioner Usage........................................176 Adjusting Operator's Seat (Air Suspension Type Seat)..............................177 Rear Tray.........................................................................178 Electric Power Output (Optional)..............................................178 Fuse Box......................................................................179 Hot/Cool Box..................................................................181 Tray and Drink Holder.........................................................181 ROPS Cab..........................................................................182 Front Interior Light..........................................................184 Rear Interior Light...........................................................184 Sun Visor.....................................................................185 Emergency Exit Hammer.........................................................185 Coat/Hat Hook.................................................................185 Upper Switch Panel (Optional).................................................186 Rotary Light Switch (Optional)................................................186 Outside Rear View Mirror......................................................187 Inside Rear View Mirror.......................................................187 Cab Door......................................................................187 Door Lock Knob................................................................188 Door Open/Close Lever.........................................................188 Window Open/Close Levers......................................................188 When Fully Opening the Door...................................................189 Cab Door Release Lever........................................................189 Battery Disconnect Switch.........................................................190 Articulation Lock Bar.............................................................192 Towing Pin........................................................................193 Inspection/Maintenance Side Access Cover..........................................194 Rear Grille.......................................................................195 Steps.............................................................................196 Tool Box..........................................................................196 Vandal-Resistant Devices..........................................................197 2 BREAK-IN............................................................................199 Break-in Period for New Machine...................................................199 Use ECO Mode for Break-in.........................................................199 3 OPERATING THE ENGINE................................................................201 Inspect Machine Daily Before Starting.............................................201 Check Before Starting.............................................................203 Starting Engine...................................................................205 Starting in Cold Weather..........................................................207 Check After Starting..............................................................208 Using Booster Batteries...........................................................209 Warm Up...........................................................................211 Cold Weather Warm Up..............................................................212 Stopping Engine...................................................................214 4 MOVING THE MACHINE..................................................................215 Driving the Machine...............................................................215 Starting to Move..................................................................216 Shift Range of Auto Transmission..............................................219 Power Mode Selector...........................................................220 Shift Change Delay Mode.......................................................220 Parking Brake Switch..........................................................221 Drive Speed Change................................................................222 Changing Forward/Reverse Drive Direction..........................................222 Steering Wheel....................................................................223 Secondary Steering (Optional).....................................................224 Emergency Stop and Restart of Operation...........................................225 Precautions for Driving on Slopes.................................................228 Precautions to be Taken if Machine Failure Occurs.................................229 Stop the Machine..................................................................230 Parking...........................................................................232 Emergency Stopping................................................................233 5 OPERATING THE MACHINE...............................................................235 Loading Control Levers............................................................235 Fingertip Control Type........................................................235 Loading Multi-Function Joystick Lever (Optional)..............................237 Control Lever Lock................................................................238 Declutch Position Switch..........................................................239 Adjustment of Bucket Auto Leveler.................................................240 Adjustment of Dual Lift Arm Auto Leveler..........................................242 Auto Idling Stop..................................................................243 Exhaust Filter Manual Regeneration................................................245 Before Operation..................................................................247 Precautions for Operation.........................................................247 Ensure Safety When Operating on Road Shoulders....................................247 Avoid Overloading.................................................................248 Avoid Rapid Steering Changes and/or Sudden Braking................................248 Avoid Operation with Loads on Only One Side.......................................248 Excavation........................................................................249 Grading...........................................................................251 Loading...........................................................................252 Dozing............................................................................255 Stock Piling......................................................................255 Removing Snow.....................................................................256 Lifting Wheel Loader..............................................................256 Precautions for After Operation...................................................257 6 TRANSPORTING........................................................................259 Transporting by Road..............................................................259 Loading / Unloading on Trailer....................................................260 Fastening Machine for Transporting................................................262 Transporting Wheel Loader (Urgent Situation)......................................263 Towing Method.....................................................................267 Lifting Machine...................................................................268 7 MAINTENANCE.........................................................................269 Correct Maintenance and Inspection Procedures.....................................269 Check the Hour Meter Regularly....................................................271 Maintenance Guide Table...........................................................274 Preparations for Inspection and Maintenance.......................................275 Articulation Lock.................................................................277 Inspection/ Maintenance Access Side Cover.........................................278 Rear Grille.......................................................................279 Periodic Replacement of Parts.....................................................280 Inspection and Maintenance Table......................................................281 Kind of Oils..........................................................................285 Recommended Grease................................................................285 Recommended Engine Oil............................................................285 Recommended Transmission Oil......................................................286 Recommended Axle Oil..............................................................286 Recommended Hydraulic Oil.........................................................287 Recommended Coolant...............................................................287 A. Greasing...........................................................................288 B. Engine.............................................................................293 1 Check Engine Oil Level..........................................................293 2 Change Engine Oil...............................................................294 3 Replace Engine Oil Filter.......................................................296 C. Power Train........................................................................297 1 Check Transmission Oil Level....................................................297 2 Change Transmission Oil.........................................................298 3 Change Transmission Oil Filter..................................................298 4 Change Axle Oil.................................................................301 5 Check Surroundings Around Axle and Covers for Oil Leaks.........................303 6 Clean Axle Housing Air Breather.................................................303 D. Hydraulic System...................................................................304 1 Check Hydraulic Oil Level.......................................................306 2 Change Hydraulic Oil............................................................307 Bleed Air from the Hydraulic System...........................................309 3 Clean Suction Filter............................................................310 4 Replace Pilot Oil Filter........................................................311 5 Replace Hydraulic Tank Oil Return Filter........................................313 6 Replace Air Breather Element....................................................314 7 Check Pilot Circuit Accumulator Function, Gas Leakage, Looseness, and Damage....315 8 Replace Pilot Circuit Accumulator...............................................316 9 Check Ride Control Accumulator Function, Gas Leakage, Looseness, and Damage.....316 10 Check Gas Pressure in Ride Control Accumulator.................................316 11 Check Gas Pressure in Steering Accumulator.....................................316 Check Hoses and Lines.............................................................317 E. Fuel System........................................................................322 1 Check Fuel Level................................................................322 2 Drain Water and Sediment from Fuel Tank.........................................324 3 Drain Fuel Filter / Water Separator.............................................325 Draining Procedures (Main Filter).............................................325 Draining Procedures (Pre-Filter)..............................................326 Bleed Air from the Fuel System................................................327 4 Replace Fuel Main Filter Element................................................329 5 Replace Fuel Pre-Filter Element.................................................330 6 Clean Fuel Pump Strainer........................................................331 7 Check Water Separator (Optional)................................................332 8 Check Fuel Hoses................................................................334 F. Air Cleaner........................................................................335 1 Clean and Replace Air Cleaner Element...........................................335 G. Cooling System.....................................................................336 1 Check Coolant Level.............................................................337 2 Check Drive Belt................................................................338 3 Check Drive Belt Tension........................................................338 4 Adjust Drive Belt Tension.......................................................338 5 Change Coolant..................................................................339 6 Clean Radiator/Oil Cooler Cores and Other Cooling System........................340 H. Electrical System..................................................................341 1 Batteries.......................................................................341 2 Check Monitor Functions and All Other Instrument Operation......................345 3 Check Work Lights...............................................................346 4 Check Horn and Backup Alarm.....................................................346 5 Check Electrical Harnesses and Fuses............................................347 I. Brake System.......................................................................349 1 Check Right and Left Brake Interlocking Performance.............................349 2 Check Parking Brake Force.......................................................350 3 Check Accumulator Function, Gas Leakage, Looseness, and Damage..................351 4 Check Gas Pressure in Accumulator...............................................352 5 Check Brake Disks (Service and Parking).........................................352 J. Tire...............................................................................353 1 Check and Replace Tire (Tire Pressure)..........................................353 2 Check Tire for Damage...........................................................353 3 Check Wheel Bolt Torque.........................................................354 K. Air Conditioner....................................................................359 1 Clean/Replace Air Conditioner Circulation/Fresh Air FiltersClean filters........359 2 Check Air Conditioner...........................................................362 3 Check Air Conditioner Piping....................................................362 4 Check Air Conditioner Condenser.................................................363 5 Check Air Conditioner Fan Belt..................................................363 6 Check Refrigerant...............................................................364 7 Check Compressor and Pulley.....................................................364 L. Exhaust Filter.....................................................................365 1 Check and Clean Filter Element of Exhaust Filter................................365 2 Check and Clean Exhaust Filter..................................................365 M. Miscellaneous......................................................................366 1 Check Bucket Teeth and Cutting Edge.............................................366 2 Check and Replace Seat Belt and Lower Tether....................................367 3 Check ROPS cab, Resin Cab Roof, and Roof Mounting Bolts.........................367 4 Check Windshield Washer Fluid Level.............................................367 5 Check Play Amount in Steering Wheel Movement....................................368 6 Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise..............369 7 Check Rearview Mirror and Inside Rearview Mirror................................370 8 Check Steps and Handrails for Damage and Looseness..............................370 9 Clean Engine Compartment and Hood...............................................371 10 Check Sound Absorbing Mat Around Engine........................................371 11 Check Engine Cylinder Head and Manifold........................................371 12 Check and Adjust Valve Clearance...............................................371 13 Check Engine Compression Pressure..............................................372 14 Check and Clean Starter and Alternator.........................................372 15 Check and Clean EGR Device.....................................................372 16 Clean EGR Cooler...............................................................372 17 Check Turbocharger.............................................................372 18 Check and Clean Fuel Injector..................................................372 19 Retighten Front Axle and Rear Axle Support Mounting Bolts......................372 20 Check Tightening Torque of Nuts and Bolts......................................373 9 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS..................................383 Precautions for Maintenance During Cold Weather Season............................384 10 STORAGE............................................................................387 Storing the Machine...............................................................387 11 Troubleshooting....................................................................391 12 Specifications.....................................................................395 INDEX.................................................................................397
Description:
Kawasaki Wheel Loader 85Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
The service manual covers the following files:
85Z7(OCE-F&S)-Attachment.pdf
85Z7(OCE-F&S)-Cover.pdf
85Z7(US-D&R)-Cover.pdf
85Z7(US-F&S)-Cover.pdf
85Z7(US-Trbl)(93211-00590).pdf
85Z7+Diagrams.pdf
85Z7+OCEA+(00580).pdf
85Z7+SM(US-DR)(93211-00600).pdf
85Z7B(US-TS)_Ecab (1).pdf
85Z7B(US-TS)_Ecab.pdf
85Z7B-TD.pdf
93311-00342.pdf
OM85Z7+USA(93111-00552).pdf
OM85Z7+USA-Cover(00552).pdf
6HK1(85Z7)Trbl+US.pdf
6HK1(85Z7)Trbl+US-Cover.pdf
6HK1(85Z7+DR)US.pdf
6HK1(85Z7+US)DR-Cover.pdf
85Z7(OCE-F&S)(93211-00660).pdf
- Our shop manuals consist of the Technical Manual, the Workshop Manual and the Engine Manual.
Information included in the Technical Manual: Technical information needed for machine pre-delivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures. Each page has a number, located on the center lower part of the page, and each number contains the following information: Example: Technical Manual: T 1-3-5 T Technical Manual 1 Section Number 3 Group Number 5 Consecutive Page Number for Each Group - Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assembly / disassembly procedures. Information included in the Engine Manual: Technical information needed for machine pre-delivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assembly / disassembly procedures
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
