This manual comes as three bound books, with part numbers 93211-00432, 93211-00441 and 93211-00450 on the covers. They cover the 85ZV-2 wheel loader from Serial No. 85C5-9001 and up, fitted with the Cummins QSC8.3 engine.
When the loader sits dead in the yard, there is usually nobody around who knows these machines. These books cover clutch pressure checks, relief settings for the loader valve and steering, brake accumulator charging and the articulation joint center pin. The wiring diagrams are split by serial range, so the harness you trace is the one on your machine.
The troubleshooting book starts from the symptom and works down to the part at fault. The chassis and Cummins fault codes shown on the MODM are listed with their meanings. Follow it through and the bucket goes back to work.
What's Inside This Kawasaki 85ZV-2 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-37 | Contents, How to Use Manual, Layout of Main Components, Maintenance Chart, Recommended Lubricants and Refill Capacity, Coolant, Weight of Main Components, Bolt Tightening Torque, Liquid Gasket |
| Measurement for Performance Check (Standard Values) | 38-43 | Engine Speeds, Clutch Pressure, Relief Valve Setting Pressures, Cycle Times |
| Chassis Group: Function, Structure and Adjustment | 44-59 | Center Pin, Front and Rear Axle, Axle Nut Tightening Procedure |
| Power Group: Cummins QSC8.3 Engine, Cooling and Drive Shafts | 60-91 | Engine Mount, Radiator, Fan Motor Line, Propeller Shaft, Engine Oil Pressure Measurement |
| Torque Converter and Transmission | 92-123 | Torque Converter, Clutch Solenoid Valve, Modulation, Trimmer Engagement, Clutch Pressure Check |
| Hydraulic Group: Function, Structure and Adjustment | 124-247 | Hydraulic Pumps, Multiple Control Valve, Pilot Valve, Orbitrol, Steering Valve, Ride Control Accumulator, Relief Valve Setting Pressures |
| Brake Group | 248-289 | Service Brake, Brake Valve, Accumulator, Unloader Valve, Parking Brake |
| Electrical Group | 290-403 | Fuse Box, Engine Start Circuit, Mcu, Modm, Engine Fault Codes, Error Codes |
| Operator Station Group | 404-487 | Cab, Air Conditioner, Steering Column, Operator Seat |
| Drawings and Diagrams (Index, Hydraulic Circuit, Wiring Diagrams, MODM) | 488-563 | Index, Axle and Transmission Drawings, Hydraulic & Brake Circuit, Electrical Wiring Diagrams by Serial Range, MODM Operation |
| Disassembly & Reassembly: General Information | 564-590 | Weight of Main Components, Bolt and Hose Band Tightening Torque, Welding Repair Cautions, Bearing Handling, Articulation Stopper |
| Disassembly & Reassembly: Chassis Group and Service Standard | 591-624 | Deck, Fuel Tank, Hydraulic Tank, Engine Room, Center Pin |
| Disassembly & Reassembly: Power Group and Service Standard | 625-692 | Engine Removal and Installation, Radiator, Front and Rear Axle, Differential |
| Disassembly & Reassembly: Torque Converter and Transmission | 693-746 | Transmission Assembly, Clutch Packs, Torque Converter Assembly Bolt Tightening Torque |
| Disassembly & Reassembly: Hydraulic Group and Service Standard | 747-824 | Hydraulic Pump Removal and Installation, Hydraulic Cylinders, Multiple Control Valve, Orbitrol |
| Disassembly & Reassembly: Brake Group and Service Standard | 825-862 | Service Brake Discs, Brake Valve, Unloader Valve Removing and Installing, Parking Brake |
| Disassembly & Reassembly: Operator Station and Index | 863-889 | Cab, Air Conditioner, Periodical Inspection/Servicing, Index |
| Troubleshooting | 890-948 | Quick Troubleshooting Tables (Torque Converter and Transmission, Hydraulic, Brake, Electrical), Error Codes for Chassis and Engine |
| Measurement for Performance Check (Procedures) and Maintenance Log | 949-1007 | Engine Speed, Clutch Pressure, Relief Pressure Setting, Accumulator Charging Time, Brake Pedal Applications, Maintenance Log |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine | Cummins QSC8.3 | p. 19 |
| Engine oil refill capacity | 33 liter (change every 500 hours) | p. 23 |
| Transmission oil refill capacity | 38 liter (change every 1,000 hours) | p. 23 |
| Hydraulic tank oil capacity | 130 liter (change every 2,000 hours) | p. 23 |
| Fuel tank capacity | 300 liter | p. 23 |
| Differential & planetary oil (front / rear) | 74 liter / 80 liter | p. 23 |
| Low idle / high idle (Normal) | 800±50 / 2,250±50 min-1 (rpm) | p. 40 |
| Torque converter stall speed | 2,250±100 (Normal) / 2,050±100 (Fuel efficient mode) min-1 | p. 40 |
| Loading line main relief pressure (HI) | 20.6±0.5 MPa (210±5 kgf/cm2) (2,986±71 psi) | p. 41 |
| Loading line overload relief pressure (LI) | 23.5±0.5 MPa (240±5 kgf/cm2) (3,413±71 psi) | p. 41 |
| Steering line main relief pressure (HI) | 20.6±0.5 MPa (210±5 kgf/cm2) (2,986±71 psi) | p. 41 |
