Kawasaki Wheel Loader 85ZV2 TMV2 Workshop Manual + Parts Catalog Manual

Description

Kawasaki Wheel Loader 85ZV2 TMV2 Workshop Manual + Parts Catalog Manual 

File Details:

Kawasaki Wheel Loader 85ZV2 TMV2 Workshop Manual + Parts Catalog Manual 

Language : English
Pages : 500+
Size : 130 MB
Downloadable : Yes
Format : PDF

KAWASAKI WHEEL LOADER 85ZV2 TMV2 WORKSHOP MANUAL + PARTS CATALOG MANUAL:

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Table of Contents:

Kawasaki Wheel Loader 85ZV2 TMV2 Workshop Manual + Parts Catalog Manual 

85ZV-2 General Information …………………………………………………………………………………………………………………. 00-1
Symbols ………………………………………………………………………………………………………………………………………… 00-2
Weight of Main Components …………………………………………………………………………………………………………….. 00-3
Bolt Tightening Torque …………………………………………………………………………………………………………………….. 00-4
Hose Band Tightening Torque …………………………………………………………………………………………………………… 00-8
Liquid Gasket and Screw Lock Agent ………………………………………………………………………………………………… 00-9
Cautions regarding parts removal ………………………………………………………………………………………………… 00-9
Cautions regarding reassembly …………………………………………………………………………………………………… 00-9
Screw lock agent application procedure ……………………………………………………………………………………… 00-10
How to wind a seal tape ……………………………………………………………………………………………………………. 00-10
Cautions Regarding Welding Repair Service ………………………………………………………………………………………00-11
Cautions Regarding Handling of Bearing ………………………………………………………………………………………….. 00-13
Bearing installation cautions ……………………………………………………………………………………………………… 00-13
Interference fits for a bearing …………………………………………………………………………………………………….. 00-13
Bearing removal cautions …………………………………………………………………………………………………………. 00-14
Applying and Storing Articulation Stopper …………………………………………………………………………………………. 00-15
Applying articulation stopper ……………………………………………………………………………………………………… 00-15
Storing articulation stopper ……………………………………………………………………………………………………….. 00-15
85ZV-2 Disassembly & Reassembly Chassis Group ……………………………………………………………………………….. 14-1
Deck ……………………………………………………………………………………………………………………………………………… 14-2
Deck removing and installing ………………………………………………………………………………………………………. 14-2
Fuel Tank ………………………………………………………………………………………………………………………………………. 14-4
Fuel tank removing and installing ………………………………………………………………………………………………… 14-4
Hydraulic Tank ……………………………………………………………………………………………………………………………….. 14-5
Hydraulic tank removing and installing …………………………………………………………………………………………. 14-5
Engine Room …………………………………………………………………………………………………………………………………. 14-8
Engine room removing and installing ……………………………………………………………………………………………. 14-8
Cab ………………………………………………………………………………………………………………………………………………14-11
Cab removing and installing ………………………………………………………………………………………………………..14-11
Floor Board ………………………………………………………………………………………………………………………………….. 14-13
Floor board removing and installing ……………………………………………………………………………………………. 14-13
Boom …………………………………………………………………………………………………………………………………………… 14-16
Boom removing and installing ……………………………………………………………………………………………………. 14-16
Center Pin ……………………………………………………………………………………………………………………………………. 14-19
Upper center pin ………………………………………………………………………………………………………………………. 14-19
Lower center pin ………………………………………………………………………………………………………………………. 14-20
Center pin removing and installing ……………………………………………………………………………………………… 14-21
Partition Plate ……………………………………………………………………………………………………………………………….. 14-25
Partition plate removing and installing ………………………………………………………………………………………… 14-25
85ZV-2 Service Standard Chassis Group ………………………………………………………………………………………………. 15-1
Linkage ………………………………………………………………………………………………………………………………………….. 15-2
Linkage Pin Standard Clearance Values …………………………………………………………………………………………….. 15-3
Liner clearance adjustment …………………………………………………………………………………………………………. 15-3
Center Pin ……………………………………………………………………………………………………………………………………… 15-4
Center pin shim adjustment ………………………………………………………………………………………………………… 15-4
Bearing cover installing ………………………………………………………………………………………………………………. 15-4
Lower center pin bearing outer ring installing ………………………………………………………………………………… 15-5
Attachment Leveler …………………………………………………………………………………………………………………………. 15-6
Attachment leveler …………………………………………………………………………………………………………………….. 15-7
Attachment leveler adjustable angle …………………………………………………………………………………………….. 15-7
85ZV-2 Disassembly & Reassembly Power Group ………………………………………………………………………………….. 24-1
Power Line …………………………………………………………………………………………………………………………………….. 24-2
Power line tightening torque ………………………………………………………………………………………………………… 24-2
Radiator …………………………………………………………………………………………………………………………………………. 24-3
Radiator tightening torque …………………………………………………………………………………………………………… 24-3
Radiator removing and installing ………………………………………………………………………………………………….. 24-5
Fan ……………………………………………………………………………………………………………………………………………….. 24-8
Fan removing and installing ………………………………………………………………………………………………………… 24-8
Engine …………………………………………………………………………………………………………………………………………. 24-10
Engine removing and installing ………………………………………………………………………………………………….. 24-10
Propeller Shaft ……………………………………………………………………………………………………………………………… 24-13
Propeller shaft removing and installing ……………………………………………………………………………………….. 24-13
Air Cleaner …………………………………………………………………………………………………………………………………… 24-15
Air cleaner removing and installing …………………………………………………………………………………………….. 24-15
Muffler …………………………………………………………………………………………………………………………………………. 24-17
Muffler removing and installing ………………………………………………………………………………………………….. 24-17
Front Axle Assembly ……………………………………………………………………………………………………………………… 24-18
Front axle assembly tightening torque ………………………………………………………………………………………… 24-18
Front axle assembly removing and installing ……………………………………………………………………………….. 24-20
Front axle disassembling and assembling …………………………………………………………………………………… 24-23
Front axle assembly cautions ……………………………………………………………………………………………………. 24-27
Internal Gear Hub …………………………………………………………………………………………………………………………. 24-32
Internal gear hub disassembling and assembling …………………………………………………………………………. 24-32
Spider Assembly …………………………………………………………………………………………………………………………… 24-35
Spider assembly disassembling and assembling ………………………………………………………………………….. 24-35
Special Tool ………………………………………………………………………………………………………………………………….. 24-37
Special tool for axle ………………………………………………………………………………………………………………….. 24-37
Rear Axle Assembly ………………………………………………………………………………………………………………………. 24-42
Rear axle assembly tightening torque …………………………………………………………………………………………. 24-42
Rear axle assembly removing and installing ………………………………………………………………………………… 24-44
Rear axle disassembling and assembling ……………………………………………………………………………………. 24-46
Axle Support ………………………………………………………………………………………………………………………………… 24-47
Axle support tightening torque …………………………………………………………………………………………………… 24-47
Axle support disassembling and assembling ……………………………………………………………………………….. 24-48
Differential Assembly …………………………………………………………………………………………………………………….. 24-50
Differential assembly removing and installing ………………………………………………………………………………. 24-50
Differential assembly disassembling and assembling ……………………………………………………………………. 24-53
85ZV-2 Service Standard Power Group …………………………………………………………………………………………………. 25-1
Propeller Shaft Service Standard ………………………………………………………………………………………………………. 25-2
Axle and Differential Service Standard ……………………………………………………………………………………………….. 25-3
Axle group ………………………………………………………………………………………………………………………………… 25-3
Differential ………………………………………………………………………………………………………………………………… 25-4
85ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group ……………………………………….. 34-1
Torque Converter and Transmission Assembly …………………………………………………………………………………… 34-2
Torque converter and transmission assembly tightening torque ……………………………………………………….. 34-2
Torque converter and transmission assembly removing and installing ………………………………………………. 34-3
Torque Converter Assembly ……………………………………………………………………………………………………………..34-11
Torque converter assembly bolt tightening torque ………………………………………………………………………….34-11
Torque converter assembly disassembling and assembling …………………………………………………………… 34-12
Transmission Assembly …………………………………………………………………………………………………………………. 34-19
Transmission assembly bolt tightening torque ……………………………………………………………………………… 34-19
Transmission assembly disassembling and assembling ………………………………………………………………… 34-20
Transmission Forward/Reverse Clutch Pack …………………………………………………………………………………….. 34-31
Forward/reverse clutch pack disassembling and assembling …………………………………………………………. 34-31
Transmission 1st/3rd Speed Clutch Pack ………………………………………………………………………………………….. 34-34
Transmission 1st/3rd speed clutch pack disassembling and assembling …………………………………………. 34-34
Transmission 2nd Speed Clutch Pack ………………………………………………………………………………………………. 34-36
Transmission 2nd speed clutch pack disassembling and assembling ……………………………………………… 34-36
Transmission 4th Speed Clutch Pack ……………………………………………………………………………………………….. 34-38
Transmission 4th speed clutch pack disassembling and assembling ………………………………………………. 34-38
Control Valve Assembly …………………………………………………………………………………………………………………. 34-41
Control valve tightening torque ………………………………………………………………………………………………….. 34-41
Control valve removing and installing …………………………………………………………………………………………. 34-42
Control valve disassembling and assembling ………………………………………………………………………………. 34-44
85ZV-2 Service Standard Torque Converter and Transmission Group ………………………………………………………. 35-1
Transmission Assembly …………………………………………………………………………………………………………………… 35-2
Control Valve ………………………………………………………………………………………………………………………………….. 35-3
Gear Pump …………………………………………………………………………………………………………………………………….. 35-5
Gear pump specifications ……………………………………………………………………………………………………………. 35-5
Clutch Plate Thickness/Piston Stroke ………………………………………………………………………………………………… 35-6
Clutch plate ………………………………………………………………………………………………………………………………. 35-7
Piston stroke …………………………………………………………………………………………………………………………….. 35-7
Clutch Oil Pressure …………………………………………………………………………………………………………………………. 35-8
Clutch oil pressure standard value ……………………………………………………………………………………………….. 35-8
85ZV-2 Disassembly & Reassembly Hydraulic Group ……………………………………………………………………………… 44-1
Hydraulic Parts Removal and Installation Warning ………………………………………………………………………………. 44-2
Hydraulic Parts Disassembly and Assembly Cautions ………………………………………………………………………….. 44-3
Hydraulic parts disassembly cautions …………………………………………………………………………………………… 44-3
Hydraulic parts assembly cautions ……………………………………………………………………………………………….. 44-3
Hydraulic Pump Assembly ……………………………………………………………………………………………………………….. 44-4
Hydraulic pump assembly removing and installing …………………………………………………………………………. 44-4
Hydraulic pump assembly disassembling and assembling ………………………………………………………………. 44-5
Hydraulic Cylinder …………………………………………………………………………………………………………………………… 44-8
Boom cylinder removing and installing …………………………………………………………………………………………. 44-8
Bucket cylinder removing and installing ………………………………………………………………………………………..44-11
Steering cylinder removing and installing …………………………………………………………………………………….. 44-13
Hydraulic cylinder disassembling and assembling ………………………………………………………………………… 44-15
Pilot Valve (S/N 9001~9214) …………………………………………………………………………………………………………… 44-21
Pilot valve removing and installing ……………………………………………………………………………………………… 44-21
Pilot valve disassembling and assembling …………………………………………………………………………………… 44-23
Pilot Valve (S/N 9215~) ………………………………………………………………………………………………………………….. 44-32
Pilot valve removing and installing ……………………………………………………………………………………………… 44-32
Pilot valve disassembling and assembling …………………………………………………………………………………… 44-34
Multiple Control Valve ……………………………………………………………………………………………………………………. 44-42
Multiple control valve removing and installing ………………………………………………………………………………. 44-42
Multiple control valve disassembling and assembling …………………………………………………………………… 44-45
Orbitrol® ………………………………………………………………………………………………………………………………………. 44-49
Orbitrol® removing and installing ………………………………………………………………………………………………… 44-49
Orbitrol® disassembling and assembling …………………………………………………………………………………….. 44-51
Steering Valve ………………………………………………………………………………………………………………………………. 44-59
Steering valve removing and installing ………………………………………………………………………………………… 44-59
Steering valve disassembling and assembling …………………………………………………………………………….. 44-61
Stop Valve ……………………………………………………………………………………………………………………………………. 44-64
Stop valve removing and installing ……………………………………………………………………………………………… 44-64
Stop valve disassembling and assembling ………………………………………………………………………………….. 44-66
Fan Motor …………………………………………………………………………………………………………………………………….. 44-68
Fan motor removing and installing ……………………………………………………………………………………………… 44-68
85ZV-2 Service Standard Hydraulic Group …………………………………………………………………………………………….. 45-1
Hydraulic Cylinder …………………………………………………………………………………………………………………………… 45-2
Pilot Valve ……………………………………………………………………………………………………………………………………… 45-4
Steering Valve ………………………………………………………………………………………………………………………………… 45-6
85ZV-2 Disassembly & Reassembly Brake Group ………………………………………………………………………………….. 54-1
Unloader Valve ……………………………………………………………………………………………………………………………….. 54-2
Unloader valve removing and installing ………………………………………………………………………………………… 54-2
Unloader valve disassembling and assembling ……………………………………………………………………………… 54-4
Manifold Valve Assembly …………………………………………………………………………………………………………………. 54-8
Valve assembly removing and installing ……………………………………………………………………………………….. 54-8
Valve assembly disassembling and assembling …………………………………………………………………………….. 54-9
Accumulator …………………………………………………………………………………………………………………………………. 54-11
Accumulator removing and installing ………………………………………………………………………………………….. 54-11
Accumulator disassembling and assembling ……………………………………………………………………………….. 54-13
Nitrogen gas charging ………………………………………………………………………………………………………………. 54-15
Brake Valve ………………………………………………………………………………………………………………………………….. 54-17
Brake valve removing and installing ……………………………………………………………………………………………. 54-17
Brake valve disassembling and assembling ………………………………………………………………………………… 54-19
Service Brake ……………………………………………………………………………………………………………………………….. 54-25
Service brake disassembling and assembling ……………………………………………………………………………… 54-25
Parking Brake Actuator ………………………………………………………………………………………………………………….. 54-26
Parking brake actuator removing and installing ……………………………………………………………………………. 54-26
Parking brake actuator adjusting ………………………………………………………………………………………………… 54-27
Parking brake actuator disassembling and assembling …………………………………………………………………. 54-28
Parking Brake ……………………………………………………………………………………………………………………………….. 54-31
Parking brake removing and installing / disassembling and assembling ………………………………………….. 54-31
85ZV-2 Service Standard Brake Group ………………………………………………………………………………………………….. 55-1
Brake Valve ……………………………………………………………………………………………………………………………………. 55-2
Service Brake …………………………………………………………………………………………………………………………………. 55-4
Parking Brake …………………………………………………………………………………………………………………………………. 55-5
85ZV-2 Disassembly & Reassembly Operator Station Group ……………………………………………………………………. 74-1
Air Conditioner ……………………………………………………………………………………………………………………………….. 74-2
Air conditioner removing and installing …………………………………………………………………………………………. 74-2
Air conditioner disassembling and assembling ………………………………………………………………………………. 74-4
85ZV-2 Service Standard Operator Station Group …………………………………………………………………………………… 75-1
Air Conditioner ……………………………………………………………………………………………………………………………….. 75-2
Periodical Inspection/Servicing ……………………………………………………………………………………………………. 75-2
Tightening Torque ……………………………………………………………………………………………………………………… 75-2

Description:

Kawasaki Wheel Loader 85ZV2 TMV2 Workshop Manual + Parts Catalog Manual 

• 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. Disassembly & Reassembly Service Standard 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.

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]